Part 1
Towbar, hitch
INTRODUCTION
- Read through all of the instructions before starting installation.
- Notifications and warning texts are for your safety and to minimize the risk of something breaking during installation.
- Ensure that all tools stated in the instructions are available before starting installation.
- Certain steps in the instructions are only presented in the form of images. Explanatory text is also given for more complicated steps.
- In the event of any problems with the instructions or the accessory, contact your local Volvo dealer.
Towbar, hitch
Note! Some steps in these installation instructions are presented with illustration only.
Applies to all models
Applies to cars with skid plate
- Drill out the four rivets at the lower edge of the skid plate. Drill carefully so that the holes in the skid plate and bumper cover are not enlarged.
Use a - 6 mm (15/64") drill bit.
- Remove any swarf and rivet residue.
- Slid the skid plate up and unhook the from five holder (1) hooks at the upper edge.
Note! Handle the skid plate with care and beware of painted surfaces.
Applies to cars with R-design
- Remove the clips.
- Repeat the operation on the other side.
Applies to all models
Illustration A
Note! Two persons should perform the following work.
- Carefully pull off the end of the bumper at the front edge from the catches on both sides. Then carefully pull away the ends of the bumper cover until the catches at the rear edge of the rear wing and under the tail lights release.
- Pull the bumper cover backwards to remove it.
Illustration B
- Disconnect the connectors under the right-hand tail lamp. The catch is underneath.
Note! Applies to cars with parking assistance.
Applies to older car models
- Remove the screws.
Applies to newer car models
- Remove the pop rivets.
Use: cutting pliers
Applies to all models
- Disconnect the front rubber mounting from the car body.
- Disconnect the middle rubber mounting from the car body.
- Remove the screws from the exhaust system's rear rubber mountings and lower the silencer until it bottoms out.
- Twist the rear rubber mountings downwards.
- Remove the clips that hold the heat shield to the body.
- Pull out the heat shield.
- Remove the covers from the inside of the side members, on both sides.
- Thoroughly clean away splashes of underseal, putty or dirt from the plate surfaces on the insides of the side members where the reinforcements shall be located.
- Check that the mating surfaces inside the side members are clean. If necessary, clean opposite where the towing member is to be tightened.
- Take the towing member from the kit and insert the two side plates in the holes at the rear edge of the side members.
- Take screws and the reinforcement bar from the kit. To maintain and adjust the position on the towing member two people should work together when the screws are entered into the weld nuts of the towing member.
Note! Ensure that the reinforcement bar is positioned correctly, according to the image.
- Tighten the screws alternately on both sides.
Tightening the screw joint
Torque tighten the screws to 140 Nm (103 lbf.ft.) and angle tighten to till 60°. When angle tightening joints in tight spaces, a protractor applied to a torque wrench cannot be used. Use instead a Hex screw head to determine the tightening angle. Use workshop lift part no. 99985972 and fixture part no. 9995972 under the silencer to position it for easier access.
- Mark the screw head flange (1).
- Make a second mark (2) in the side member or reinforcement bar.
- Now tighten the screw so that the screw head marking (1) lines up with the marking (2) on the side member/reinforcement bar.
- Repeat for all screws.
- Cut out the heat shield between the middle embossings as illustrated.
Applies to older car models
- Tighten the heat shield.
Applies to newer car models
- Rivet the heat shield.
Applies to all models
- Apply low viscosity rustproofing agent to the marked bare sheet surfaces on both sides of the collision member as well as to the rear edge of the rear side members on the right and left hand sides.
Applies to cars with R-design
- Remove the skid plate from the bumper cover.
Applies to all cars without skid plate or R-design
- Apply tape to the outside of the bumper cover, opposite the markings on the inside. This is done to protect the paint from the saw when cutting out the cut-out for the towbar.
Applies to all models
- Measure and mark up for a cut-out for the tow hitch wiring.
- Saw according to the markings. The shaded surface is to be removed.
Note! Do not damage the painted surface of the bumper cover. Cut so that the raised edge on the inside remains. The raised edge marks the cut-out
- Remove the tape.
- Smooth off the sawn edges with a fine toothed file.
- Install the tow hitch connector with the cable harness according to the appropriate installation instructions.